Method and System for Recycling an Electronic Article

ABSTRACT

Disclosed is an environmentally responsible method for recycling electronic waste. The method optimizes the transportation and delivery of electronic waste to a recycling facility utilizing plasma gasification. The method tracks and categorizes the e-waste while billing manufacturers for the electronic waste received for recycling. In the process, the electronic articles are dismantled where certain valuable components are removed and recycled. The remaining e-waste proceeds to the plasma gasification process for metal extraction and gas production.

FIELD OF THE INVENTION

The present invention generally relates to a method of recycling electronic articles at the end of their life and to a greater degree the method relates to a method of recycling electronic waste recovering valuable materials and energy using in part a plasma gasification device.

BACKGROUND

E-waste is discarded electronic equipment that, based on the perception of the user, has reached its end of its useful life. Examples of e-waste include desktop computers and monitors, laptops, printers and fax machines, cell phones, and televisions. This sector is one of the fastest growing areas within waste, increasing at a rate 3 times faster than traditional recycling materials, or on average, from 8.3% to 12% per year.

In 2007 it was estimated that over 3 million tons of e-waste was generated in the U.S with only about 14% of that amount having been recycled. The e-waste not recycled ended up in landfills or incinerators either here in the US or abroad. In a 2006 report, the International Association of Electronics Recyclers projects that with the current growth and obsolescence rate of the various categories of consumer electronics somewhere in the neighborhood of 3 billion units will be scrapped during the rest of this decade, or an average of about 400 million units a year. Some 20 to 50 million metric tons of e-waste are generated worldwide every year, compromising more than 5% of all municipal solid waste. While it's not a large part of the waste stream, e-waste shows a higher growth rate than any other category of municipal waste in the EPA's report. Overall, between 2005 and 2006, total volumes of municipal waste increased by only 1.2%, compared to 8.6% for e-waste with 68% of consumers stockpiling used or unwanted computer equipment in their homes. The EPA estimates that 234.6 million units were in storage by 2007.

E-waste is expected to continue to increase and peak by 2015 with an estimated 73 million metric tons by 2015. In addition, the rate of electronic equipment obsolescence is increasing as product life cycles have shortened. For example, the life period of a television set is now under 10 years while that of a computer is only 2-3 years. In short, consumers are trading in electronics for newer more feature rich models at an ever-increasing rate.

Electronic items such as computers, cell phones, pagers, computers, handheld global positioning systems (GPS's), MP3 players, calculators, batteries, etc. are quickly becoming a significant source of electronic waste. As technology advances, consumers are replacing such electronic items with newer models and newer equipment more and more frequently. Due to a very small after-market demand for used electronic equipment, the quantity of these materials that is being thrown away in landfills has been increasing at an alarming rate. One current estimate is that there are over 100 million used cell phones in the United States alone with at least one manufacturer replacing 250,000 cell phones monthly.

The discarding of electronic equipment creates a two-fold problem. First, the electronic equipment often contains hazardous materials such as lead, cadmium, mercury, etc. that can be of concern when discarded in an improper fashion. The second problem is that the electronic equipment may also contain valuable metals such as gold, silver, etc. that are lost.

Electronic items such as computers and cell phones contain, in addition to plastics and other organic materials, a small amount of copper, lead, tin, gold, iron, aluminum, zinc, cadmium, etc. The more abundant valuable materials, including gold and silver would be worth recovering if there existed an efficient and economic process to perform such recovery.

E-waste recycling systems are scarce in the U.S.; as a result, businesses and individual consumers experience difficulty when attempting to recycle electronic devices. Consumers often face a lengthy trip to utilize the nearest recycler and a high cost for recycling their e-waste when they arrive. In addition, interstate recycling (made necessary by the scarcity of programs), compounded with unclear regulation, inflates the cost of recycling. As a result of these disincentives to domestic recycling, only 20% of all E-waste in the U.S is recycled and as much as 50-80% does not enter landfills and, instead, is exported to developing countries, where hazardous material regulations are less severe or nonexistent. Unsafe recycling practices in these countries can render the recycling process highly hazardous to workers, and often create even greater health hazards to the general community than disposal in landfills.

Thus, what is needed is a method for recycling electronic articles that both encourage the recycling of the articles along with not being an environmental hazard.

SUMMARY

The present invention provides an environmentally responsible method for recycling electronic article while substantially reducing exposure of hazardous electronic waste to the environment. The method optimizes the transportation and delivery of electronic waste to a recycling facility utilizing plasma gasification. The method recycles the whole electronic article, components that cannot be salvaged are processed in the plasma generator and reduced to elemental components. Additionally, payments are received from manufacturers for recycling electronic articles produced by them.

In greater detail, the method of recycling electronic waste includes providing an electronic article for recycling and delivering the article to a recycling facility. The article is then processed using plasma gasification, whereby the article is broken down into elemental components. The method includes a fee received for recycling the article from the manufacturer of the article. The method further includes the step of dismantling the article which typically occurs prior to the gasification step.

Additionally, the method includes producing a salable electricity and the recovery of metals from the articles. The electronic waste can be collected by the electronics distributor such as a retailer. The delivery of the electronic article for recycling can be initiated by the consumer or by the electronics distributor. Electronic waste can also be provided by a government body or an electronics waste recycler. The electronic article can be labeled or tagged whereby valuable components of the electronic article can be identified and removed in the step of dismantling the article. The electronic article is also tracked electronically in a computer database and reported.

In a further embodiment, the consumer initiates the delivery of the article to the recycling facility via a web based interface whereby by the article is picked up and information is entered into a database including the make and manufacturer of the article. Additionally, the method may include the generation of carbon credits and the receipt of government electronic collection fees. The method further can be energy self-sufficient and in a further embodiment the method can produce a surplus energy in the form of electricity production and a gas such as syngas and hydrogen.

In an additional embodiment the method includes a computer program product for providing recycling information for an article to be recycled. The computer program product includes a computer usable medium having computer readable program means for causing a computer to perform the steps of determining the manufacturer and make of the article and tracking the article in the recycling process and the computer optimizing the delivery of the article to a recycling facility. The computer program also includes the computer determining and reporting components of the article for removal and recycling. The program can further determine a pickup of the article for delivery and associated fees received from the manufacturer of the article.

DRAWINGS

In the Drawings:

FIG. 1 illustrates an embodiment of the present method showing the collection of e-waste and the transportation of the same to be recycled using the plasma gasification process and the sale of the resultant components;

FIG. 2 depicts a further embodiment of the method illustrating the collection methods of the e-waste and the dismantling of the e-waste; and

FIG. 3 illustrates the plasma gasification process of the e-waste and the resulting products of metals, vitrified glass and electricity which can be generated using steam turbines via steam generated by the heat of the plasma apparatus.

DETAILED DESCRIPTION

Disclosed is an environmentally responsible method for recycling electronic articles while substantially reducing hazardous waste. The method optimizes the transportation and delivery of electronic articles to a recycling facility utilizing plasma gasification. The electronic articles are dismantled at the facility and certain valuable components are removed and recycled. The remaining e-waste proceeds to the plasma gasification process for metal extraction and gas production. Additionally, the method includes receiving payments from manufacturers for recycling the electronic articles produced by them.

In greater detail the method derives in an embodiment income from three separate sources. In an embodiment income is obtained on a business to business interaction. Income can be derived from electronic manufactures, government electronics collection fees and revenue from recycled materials and plasma by-products. Income or fees from electronics manufactures can be the extended producer responsibility fees currently paid by the manufactures in return for the recycling of the manufacturer's end of life electronic article. Additionally, the fees may be the advanced recycling fees which are paid by the consumer at the time of sale of the electronic article to be recycled. The present method provides the complete recycling of the electrical article including the treatment of any toxins.

The method further provides the manufacturer with the ability to track each item recycled in one embodiment in real time. The method can interact directly with the customer who has the item to be recycled or through a third party such as a retailer or manufacturer. Typically, a stand alone website may interact directly with the customer and an open source software design can be adapted by manufacturers and retailers. In either embodiment, incentives may be provided to encourage the customer to recycle the end of life electronic item. The incentive can be an offer for a discount or store credit if the customer purchases a new item.

The method further includes forming relationships with electronic manufacturers, electronic retailers and shipping carriers. In the relationship with electronic manufacturers the method may include an exclusive contractual relationship to provide all the recycling needs of the manufacturer. In the relationship with retailers, the retailers may use their existing shipping network that delivers inventory to their stores from the distribution warehouses which can provide a pickup point for the e-waste which can be picked up in bulk to reduce costs.

The relationship with carriers can be one of a contractual relationship. The method is not time sensitive and the electronic articles can travel by the least inexpensive means not restricted by any time deadline. The method in an embodiment may include a direct consumer shipment method wherein upon initiating a consumer electronic article return a package may be shipped to the customer to include the electronic article in the container. The shipping container can include a tracking number through the carriers website that can be tracked to ensure the electronic article reaches its destination securely and un-tampered with preventing data integrity losses.

Shipping may also be done capitalizing on the existing logistical networks currently employed by the electronic retailers. Retailers already have a shipment operation that allows for them to deliver from their warehouse distribution centers to the network of store locations across the country. In an arrangement with these retailers, there could be an agreement to transport the collected electronic articles back to their distribution centers. The method can then capture these collected electronic articles from a more centralized location for mass transit.

Referring now in greater detail to the drawings in which like numerals indicate like parts throughout the several views, FIGS. 1-3 depict the present method in various embodiments of the present invention.

FIG. 1 illustrates an embodiment of the present method showing the collection of e-waste or electronic articles to be recycled. The terms “e-waste” and “electronic article” to be recycled are used herein interchangeably. The figure also shows the transportation of the same to be recycled using the plasma gasification process and the sale of the resultant components.

The method shown in FIG. 1 includes providing an electronic article for recycling and delivering the article to a recycling facility. The article is then processed using plasma gasification, whereby the article is broken down into elemental components. The method further includes the step of dismantling the article which typically occurs prior to the gasification step.

The method includes a fee received for recycling the article. The fee may be provided by a government body whose funds were either derived from the manufacturer or consumer purchasing the electronic item.

For example the fee may be the extended producer responsibility (EPR) fee paid by the manufacturer at the time article is made. The fee is typically paid by the manufacturer to the state or government entity to be used to cover the cost of recycling the article. Furthermore, the recycling cost may be covered at least in part using an advanced consumer recycling (ACR) fee wherein the customer pays a “tax” at the time of purchase of the article to a government body. The collected fees in both instances are used to cover the cost at least in part the future recycling cost of the electronic article at the end of its life. The method can further include receiving money in the form of tipping fees which is typically paid by haler for dumping refuse in a landfill and waste disposal site.

The term “government body” includes local, state and federal entities. It is contemplated the fees are those either collected from the manufacturer or consumer to cover at least in part the cost of recycling the electronic article. The collected fees are paid for recycling the electronic item. The term “electronic item” includes all electronic waste including electronic items in whole or in part.

Additionally, the method includes producing a salable electricity and the recovery of metals from the articles. The production of salable electricity is such electricity that can be sold to a utility. Electricity can be produced by turning a stream turbine wherein steam is produced from the heat generated by the plasma generator. Electricity can be further generated by burning the gas generated in the plasma device. Furthermore, in an embodiment the method is energy self sufficient.

In a further embodiment a carbon credit is receive in the method. The term “carbon credit” can refer to permit that allows the holder to emit one ton of carbon dioxide. The carbon credit may be issued by either government bodies or groups for the reduction green house gases. Typically, carbon credits can be traded.

In the delivery of the electronic article for recycling, the delivery can be initiated by the consumer or by the electronics distributor. The electronic article for recycling can also be provided by a government body or an electronics waste recycler. The electronic article can be labeled or tagged whereby valuable components of the electronic article can be identified and removed in the step of dismantling the article. The electronic article can also be identified optically by machine and the key components noted to a dismantler. The electronic article is also tracked electronically in a computer database and reported. The electronic waste can also be collected by the electronics distributor such as a retailer.

FIG. 2 depicts an embodiment illustrating the collection methods of the e-waste and the dismantling the electronic waste. In the figure there is shown the various pickup options of the e-waste and the transportation of the same to the recycling or processing facility. The recycling facility can be one or more buildings at one or more locations where various stages of the recycling process occur. The figure further shows the products of the plasma gasification process.

Turning now to FIG. 3, there is shown the gasification process and the resulting products of the plasma gasification process. The plasma gasification apparatus 2 can be one available from such companies as Westinghouse, GeoPlasma, Plasco Energy Group, EuroPlasma, and Hitachi Metals. In the following disclosure, the example plasma gasification apparatus is one available from Alter Nrg of Calgary Canada.

The machine 2 is shown with a gas vent 4. Various gases during the process such as syngas and hydrogen can be expelled thought this vent 4. The machine 2 further includes a plasma torch vent 6 and a slag drop 8. The drawing of the machine 8 is simple illustration of one possible embodiment of plasma gasification machine. Also shown in the drawing are the products of the plasma gasification process such as the recycled metals recovered. Such metals can include various rear earth metals.

In the operation of the machine 2 it is important to process the correct mix of electronic articles into the plasma gasification machine to produce the most optimal energy output. This process maximization step is important in creating enough energy in the gasification process to run the plant and sell the excess energy for resale back to the power grid. The byproducts of the machine include syngas and hydrogen. These resources contain large amounts of energy and have a resale value as alternative fuels. The solid materials also have a value. The machine 2 can pull the aluminum and copper out of the machine for resale after it passes through the plasma torch; and the slag byproduct can be used in other products such as asphalt and insulation.

An example plasma gasification machine includes a feed system and a plasma vessel. The feed system can simultaneously accommodate any proportion or combination of solid, liquid and gaseous feedstock. Solid wastes, depending upon their composition, can be pumped, screw fed, or ram fed into the plasma vessel. A shredder ahead of the feed system may be appropriate to achieve size reduction or object separation prior to direct system feed.

Liquid wastes, including sludge, can be pumped directly into the machine 2 through the wall of the plasma vessel through a special in-feed nozzle. The liquid feed system is designed to also accommodate any entrained solids that may be present. Similarly, gaseous feedstock may also be introduced into the plasma vessel through a specially designed nozzle.

The plasma vessel is a cylindrical two-part container made of stainless steel with an opening in the roof through which the plasma torch is inserted. The vessel is lined with insulation and refractory to allow both maximum retention of internal energy and to protect the stainless steel container from the intense heat inside the vessel. The plasma vessel is equipped with inspection ports (including a video camera so the operator can see real time images inside the vessel to assist in machines operation), openings for introduction of feedstock, and an exit port for removal of excess molten material.

The smaller vessels are designed to remove molten material periodically through an automated tipping mechanism during which time the vessel may or may not remain in continuous operation. A design enhancement incorporated into the most recently constructed system is a continuous melt extraction feature which maintains the level of molten material in the plasma vessel at or below a preset limit without interrupting the operation of the system. This melt extraction system can be deployed with all sizes of plasma gasifications.

The plasma vessel is designed to ensure that no feedstock material is able to reach the exit port without first passing through the plasma energy field and undergoing complete molecular dissociation. In addition, the plasma vessel is maintained at a slight negative pressure to ensure that no gases can escape to the atmosphere.

It should be understood that the foregoing description is only illustrative of the present invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the spirit of the present invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances that fall within the scope of the claims. 

1. A method of recycling electronic waste comprising: providing an electronic article for recycling; delivering the article to a recycling facility; and processing the article using plasma gasification, whereby the article is broken down into elemental components.
 2. The method of claim 1, wherein a fee is received for recycling the article from a government body.
 3. The method of claim 2, wherein the fee is received from a government body whereby the manufacture, consumer or combinations thereof have contributed to a fund for the cost of recycling the electronic article.
 4. The method of claim 1, wherein a salable electricity is produced and a carbon credit is received.
 5. The method of claim 1, wherein an electronic distributor collects the electronic articles.
 6. The method of claim 1, wherein a consumer initiates the delivery of the article to the recycling facility.
 7. The method of claim 1, wherein the electronic article is provided by a source including a government body, electronic waste recycler and combinations thereof.
 8. The method of claim 1, further including the step of dismantling the article.
 9. The method of claim 8, further including labeling the electronic article whereby valuable components of the electronic article can be identified and removed in the step of dismantling the article.
 10. The method of claim 1, wherein the electronic article is tracked electronically in a computer database and reported.
 11. A method of recycling electronic waste comprising: providing an electronic article for recycling; tracking the electronic article and reporting the article including the manufacturer and components of the electronic article; delivering the article to a recycling facility; receiving a fee for recycling the article from a government body; dismantling and sorting the article; and processing the article using plasma gasification, whereby the article is broken down into elemental components.
 12. The method of claim 11, wherein a consumer initiates the delivery of the article to the recycling facility via a web based interface whereby by the article is picked up and information is entered into a database including the make and manufacturer of the article.
 13. The method of claim 11, wherein electronic manufacturers, electronic distributors and combinations thereof initiate the delivery of the article to the recycling facility.
 14. The method of claim 13, further including the electronic distributors collecting the electronic articles for recycling.
 15. The method of claim 11, wherein the step of processing the article using plasma gasification produces metals, syngas and hydrogen gas, electricity and combinations thereof.
 16. A computer program product for providing recycling information for an article to be recycled, the computer program product comprising: a computer usable medium having computer readable program means for causing a computer to perform the steps of determining the manufacturer and make of the article and tracking the article in the recycling process and the computer optimizing the delivery of the article to a recycling facility.
 17. The computer program of claim 16, further including the computer determining and reporting components of the article for removal and recycling.
 18. The computer program of claim 16, further including the computer determining a pickup of the article for delivery and associated fees received from the manufacturer of the article.
 19. The computer program of claim 16, wherein the computer displays and records images of the article to be recycled during the recycling process.
 20. The computer program of claim 16, wherein the computer provides images of the destruction and recycled items and the contained hazardous compounds and percentage recycled items. 